Methods of joining blade components of wind turbine rotor blades using positioning elements

Abstract

A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

What is claimed is: 
     
       1. A method of joining first and second blade components of a rotor blade of a wind turbine, the method comprising:
 providing corresponding first and second positioning elements at an interface of the first and second blade components; 
 aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together, wherein the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components; and, 
 permanently securing the first and second blade components together via welding such that the desired spacing is maintained between the first and second blade components, wherein permanently securing the first and second blade components together via the welding further comprises welding the corresponding first and second positioning elements together and subsequently welding the first and second blade components together. 
 
     
     
       2. The method of  claim 1 , wherein the first blade component of the rotor blade comprises at least one of a pressure side shell, a suction side shell, a spar cap, a leading edge, a trailing edge, or combinations thereof and the second blade component of the rotor blade comprises at least one of a pressure side shell, a suction side shell, a spar cap, a leading edge, a trailing edge, or combinations thereof. 
     
     
       3. The method of  claim 2 , wherein the first and second blade components comprise the pressure side shell and the suction side shell, respectively, and the interface comprises a trailing edge of the rotor blade, the method further comprising:
 providing a V-shaped component at the trailing edge; and, 
 placing the corresponding first and second positioning elements on one or more sides of the V-shaped component. 
 
     
     
       4. The method of  claim 1 , wherein the corresponding positioning elements comprise at least one of recloseable fasteners, hook-and-loop fasteners, snap-fit fasteners, opposing sides of double-sided tape, one or more bump stops, or combinations thereof. 
     
     
       5. The method of  claim 1 , wherein the corresponding positioning elements are constructed from a thermoplastic material. 
     
     
       6. The method of  claim 1 , wherein providing the corresponding first and second positioning elements at the interface of the first and second blade components further comprises at least one of printing the corresponding first and second positioning elements at the interface, adhering the corresponding first and second positioning elements at the interface, or inserting the corresponding first and second positioning elements at the interface. 
     
     
       7. The method of  claim 1 , wherein aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together further comprises at least one of manually aligning and securing the first positioning element of the first blade component with the second positioning element or aligning and securing the first positioning element of the first blade component with the second positioning element via machinery. 
     
     
       8. The method of  claim 1 , further comprising permanently securing the first and second blade components together via an adhesive. 
     
     
       9. The method of  claim 8 , wherein permanently securing the first and second blade components together via the adhesive further comprises:
 aligning the corresponding first and second positioning elements together; and, 
 after aligning and without allowing the aligned first and second positioning elements to move, injecting the adhesive into one or more gaps created by the desired spacing. 
 
     
     
       10. The method of  claim 9 , further comprising:
 before injecting the adhesive, inspecting the aligned first and second positioning elements before injecting the adhesive; 
 if alignment of the first and second positioning elements is not sufficient, repositioning the first and second blade components by detaching one or more of the first and second positioning elements to allow for realignment; 
 realigning the first and second blade components; and, 
 temporarily reattaching the first and second positioning elements and reinspecting the alignment. 
 
     
     
       11. The method of  claim 9 , wherein the aligned first and second positioning elements provide and maintain smooth external mating surfaces between the first and second blade components. 
     
     
       12. The method of  claim 1 , wherein the corresponding first and second positioning elements remain part of the rotor blade. 
     
     
       13. The method of  claim 1 , wherein the corresponding first and second positioning elements are internal of an outer aerodynamic surface of the rotor blade.